Flush plug receptacle and method of manufacturing the same



I March 17, 1931. E. R KULKA 1,796,290

FLUSH PLUG RECEPTACLE AND METHOD 0F MANUFACTURING THE SAME Filed Feb. 9. 1928 2 Sheets-Sheet l March 17, 1931. E R, KULKA 1:79629() FLUSH PLUG RECEPTACLE AND METHOD OF MANUFACTURING TH SAME Filed Feb. 9. 19253 2 Sheets-5h89?. 2

INVENTOR @n mgm/21mm ATTORNEYS sie yPatented Mar. 17, 1931 1g UNITED s'frgrrEsl EUGENE n'. KULKA, O'FNEW Yonx, N. Y., nssroiron*ro c. n. kWoon ELECTRIC co. I'Ne.;

PATENT ,ori-"ICE,

or NEW YORK, N. Y.; A CORPORATION or NEW Yonxf rLUsi-r PLUG nnen-'Team AND iur'rnon or MANUFACTURING THE SAME Application filed February 9, 1928.- Serl No. 253,118'.

v My invention relates toma new and imyproved' Hush plug receptacle and avneivv and improved method of manufacturing the same.

One of the objects 'of my invention is to pro- 5 vide' a flush receptacle comprising a` body made of bakelite or other phenol condensati'on^p1-od=uet,'or lother lmaterial Which is formed under lieat'and pressure, said body having a; supportingA strap imbedded theref in andfprojecting. therefrom, said strap and body kbeing integrally united by the molding process. However, my invention is not limit- A' eel-1in 'certain aspects thereof, to a body-Which isilnolded integral withl the supporting strap,

. V1li of toacne-piecebody'madeof a coherent mass ofmoldedfmaterial. VVAnother objectof my 4invention is to provide device of thistype which issimple and economical to manufact-nrcand which shall be efficientand durable.` j v Qtlier objects ofV my invention Will be set forth inthe fol-lowing description and drawingswhicli illustratea preferredembodiment thereo'f, v itbeing understood that; they above general statement' Ofthefobjects of -rny invention is intended' t0 general-1yexplain'the same andnotto limit itin any manner- Fig.- 1 is atop vieu'7 v0i a plug receptacle Yl-)odyancl strap'. f Y v Figg 2fi s a bottomview of Fig. 1.

f ,Figis ay view similar to Fig. 2, the conmots-being omitted'.

Fig'. iis a: sectionaliview on the line 4 1 o'lE Fig.r2. v l .f 'iFig 5I is a perspective'view showing afcontact. v' f 1 Y' i 6' is' a' plan View of the supporting strap.y y

F`gl7 isa side view ofthe supporting'strap.

' Figi;l 8 is a detail sectionalview showing lioiv'tlie plug receptacle body and the contact areconnected or'as'senibled'. I v .Fg. Sisasectional viewof the insert'shown in Fig.

'efPtidem, f

Fig 11. is .a bottom view'showmg how a bottom insulatugmembel'iS Connected t0 the body'of thereceptacle-v Y `IjigllOis a sideelevationofthe completed Fig. 12 is a View similar to Fig. 1 illustrating a duplex receptacle.

Fig. 13 is al bottom'vieiv of the deviceshown in Fig. 12.

Fig. 14 is aview similar to Fig. 13, the contacts heilig omitted.

Fig. 15 is an inverted side view of the device shown in Fig. 12.

Fig. 16 is a sectional view on theline 16-16' Fig. 22'isa central section through the mold utilized for making-.articles of this type.

The device comprises a body portion `1 Which'is preferably 'made of bakelite or other phenol' condensation product having asupporting strap2, a part of which is imbedded inthe said body 1, the ends of the strap 2pm; jecting from the body l. As shown in Fig. 6 the strap'2 is providedwith anfintermediate bridge portion?y which is narrower than `the main body'of` the sta-rp 2, so that the strap 2 can extend continuously throught-he body 'l While the contacts may be located inthe recesses 4 and 54 of the strap 2, so that the con-y tacts are separated from' the strap 2 by the insulating material of which the body 1y is formed.

Since the receptacle illustrated herein is of theuniversal'type, it is provided with four longitudinal recesses 6', 7 8 and 9. The con@L tacts C have the configuration shown in Fig. andthey are provided with contact wingsor portions C and C2. Hence and as shown more particularlyin Fig. 2,the wingsC of vthe two contacts Care locatedin the corresponding recesses V6 and 8,.and the Wings C2 of said contactC are located in the other pair of corresponding recesses? andi 9. VThe wings C2 are adapted/to cooperate with a plug4 of the tandem type, and the wingsC are adapted to cooperate with the plug of the yparallel type soY that eithertype of plug be used With the plug receptacle illustrated.

` Plug receptacles of this .kindare desig` -y nated as the universal type with the trade.

As shown in Fig. 8, inserts 10 'preferably havingvknurled esteriore are connected to the receptacle 1 after the molding so that no separate fastening means are required tohold the said inserts in position. `The knurledejttey riez' of the inserts 10 is'to'prevent them from.

f thenreceptacle body.` yAs sho'vvn in Fig. 5, each` f Contact@ has a perforation Which isadapted to'fit over the reduced'end Vof* one of the contact'inserts 10, and this reduced Vend is then enlarged yby/being spun overfsoasto actjlike a Yrivetand firmly clamp the contact C in position; S 1

v The bottoni' of the receptacle is yprovided iWith a central longitudinal Arecess 12 anda .t dise 14 made of any suitable insulating mate- Y ria-l' Vis yconnected to the underside of the re ceptacle bodyl by means'of a tapered Yrivet 15 which has a drive fit'so that the insulating Y cover 14 is firmly held inposition. It Will vbe "noted in Fig; 4 that'the recess 12 extends substantiallypto the bridge portion Sfof they solid ,cartridge v'ortalolet V f' strapl.v Y t i .Y t, In order, to' d manufacture the article previouslydescribedmolds ofthe :type used'lfor' formingbakeliteare employed.

responding',tolthat part ofthe re'cep'tacl'ejl'i'odyl YWhich is shown as located above 'the vstrapV 2 in Fig. 110,v is vplaced on thefbo'ttonifo'f;the

lower moldmem'ber.

For convenience `4vthat ipartnvof. the recep` -tacle body which isik shown asbeingl :located is Vabove-fth'e strap 2 kin'.Fig..1O,Will befdesignated asthetop io'f the: device,"althoughthe' operation of the-jdeviceis ofeourse not 1de# pendent nponth'eposition in which itisxheld.

Thestrap2 isnowvplaced in properpositfion uponthis tablet or cartridgeg'the yend'sjof'said'` strap f2 projecting beyond the" topV ofthe lower moldmeinber. An imperforatetabletor car- Y Y tridge corresponding to the lower lportion 'i `of the device isnovv placed upon the; strap 2.

An upper mold Aniemberjis'noyv forced down upon the'masses ofjbakelite"andfthisuPPer faceandfhe bassine is Subjeetai ministres- A7,- 8 vand 9'y and thelcentral :recess '12. i kpuncheizerts Tahpressure 4of about tlireeftlioumold'rnembe'r is providedA vvit'h pins corre:- sponding to the fourlongitudinalopenings 6, The

sandpou'nds yperfsquare.inch of molding'sur-v isure, and` the sproper in'olding temperature, fora suitable period; namelygfor aboutl2l3 yto 'minutesf. 4During thisniolding 'operation bereitet@- 5 the preformed masses of bakelite poivder` shrink so that the prefoimed'article is' from vone and a half to twice the size of thejnallyl completed article. The bakelite powder from YWhich the tablets have been inadeiirstV be- 'I comes plastic andfthen sets.l "Since the-plane.

of thev strap'2 is substantially perpendicular V'to the central longitudinal axis of the body 1,

and sinceethat partofstrap 2,!yvhichlistojbe imbedded in the bakelite bodyis'fiotsubjected to direct Contact with tliefii i ier mold nieni- .Y

l l Y ber, it can bereadily heldin; suitable .position during the intermediate stage, namely,l While the bakelite is shrinking the heat and pressure. v

After the bakelite hasfb'een setfdue to the heat andpressurajit continues to shrink until f it has thoroi'i'ghlyl cooled: Hence; after the molding has been lcomp`leted,the inserts 10 can be forcedr into suitable recesses which 5 vhave been formedin the bakelite body by'pins located-on the upper mold member v( and 'ad-r and setting, due to,

ditionalV -toy those previously 'Y mentioned).

The inserts are forcedlin `s`o as' to have a drive litbefore the molded receptacle'bodies'have' .Y

thoroughly cooled andthe shrinkage Aof said receptacle bodies 1 due to-saidcoolingfcauses the inserts to be very firmlyfh'eld in position.

Thev contacts C are athen mounted :in .proper completed.

body lpiieviouslylv describedv save-'that it' cii'-,

Vposition 'and lthe 'assembly'V off tli'e'artiele is 35s Y sistsof'tvvo' Wings vor portionsjoonnected by.` Y

an intermediate, portiony also made' f of .bake-` lite and molded in'one pieeevvithfthe endpor-- also partially imbedded iin both halves. of the flush receptacle body 1". and it'is'provided with a series offA openings 'Ri lfor `clearing-the. contact members WhichY 'are located inthe lon-j.

gitudinal openings of ythe *receptacle The strap 2' is providedlwitha centraltappedorj internally threaded openingT Which :isV lo-v f cated in the bridge portion of thereceptacle.

so that the strap caiifbe readily connected to the c over plate of vthe outlet. boxf WithoutY requil-ing the use of anY additonalinsert. or 1in- H Vserts for this purpose.

Y The inserts :10. and the-screws llzarez-simi# lar to' those previouslyV described.y "The'cone tacts 2Ok are of the same generaltype as the 1 contacts C'previously described savefthat .each 'contact20 is provided `With four. con- .23. and V24 lwhich are' `disa;

tact Wings, 21, 22, t posed `as shown in Figgl. A second contact 2O is also providedttheg'standardjarrangenient of the VContact ivingsfbeing illustrated iiijFig. d

12.1* The moldingoperation is shovn indetail/inffigs. 21.and 22. TheiioiverpajrtM of the mold is of sufficient depth tojhold tliebot.`

toni Vbakelitei cartridge Yand the projecting Yends of the strap 2 arelocated'fuponlthetop of'vthi's` bottom: *member-5 Thestrap 2 e is preformed intotlie shapeshoivnig-l22i ingpinsPwhichform the various recesses and openings in the completed receptacle.' These pins P are shown as broken away in Fig. 22y in order to illustrate the device more clearly. Hence the central portion of the strap 2, which is completely imbedded within the bakelite body isnot subjected to direct contact with either the members M or M', but

4 theY projecting ends thereof arev firmly clamped vrin position between themembers M and M. This operation is rendered possible tudinal axis of the said body, said contacts being located inv cut-out portions of the said strap, so that said contacts are spaced from said strap by the insulating material of which the said body is composed, that portion of said strap which is imbedded in said body including a narrow diagonal metal strip inclined to the longitudinal axis of the strap.

In testimony whereof I afix my signature.

EUGENE R. KULKA.

i Y by the fact thatthe plane of the strap is per- Y Y drive fit.

pendicular to the central longitudinal aXis of the body 1. The bottom of the receptacle 1 is providedfwith a cover 14 which is also held in place by means of a rivet 15 having a The central pin P of the mold M',

' which forms the central recess 12 is preferably made longlenough to abut the corresponding part of the strap 2. y

Hence the underside of the strap is exposed so that the internalthread can be readily formed. The top of the strap corresponding to the bridge portion of the receptacle body is covered with only'a very thin layer of bakey Vlite andthis layer of bakelite may be omitted ifdesired, as it serves no useful purpose.

I have shown a preferred embodiment of my invention, but it is clear that numerous changes and omissions canbe made without departing I claim: 1. In combination, a flush receptacle' body made of moldable material, a metal supportfing strap, aV continuous portion of which is from the spirit of my invention.

n imbedded in said-body, said strap being molded integral with vsaid body, andy having its plane substantially perpendicular to the central longitudinal axis'of said body, said strap valso having portions projecting beyond said body, said body having four contacts substantially equal in distance from eachother and substantially parallel to the longitudinal axis of the said body, said contacts being located in cut-out portions of the said strap, so

` that said contacts are spaced from said'strap body is composed.V

imV l by the insulating material of which the said '2.' -In combination, a iush madevof moldable material, a metal supportj ing strap, a continuous `portion of which is imbedded 1n said ibody, said strap being molded integral with said body, and having yits plane substantially perpendicular to the ycentral longitudinal airis of said body, said lstrap also having portionsv projecting beyond lsaid bo`dy,sa.id body-,having four contacts substantially equal indistance from' leach other and substantiallyparallel to the longireceptacle body i 

